Removal Procedure

Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
Remove the oil fill cap.
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Intake Manifold Cover Bolt (1) - Remove [2x]
Lift up on the front of the intake manifold cover (2).
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Intake Manifold Cover (1) @ Upper Intake Manifold Bracket (2) - Remove
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Intake Manifold Cover Bolt (1) - Remove
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Intake Manifold Cover Insulator (1) - Remove
Raise and support the vehicle. Lifting and Jacking the Vehicle
Drain the cooling system. Cooling System Draining and Filling (L3B Static Fill) , or Cooling System Draining and Filling (L3B GE 47716)
Drain the engine oil. Engine Oil and Oil Filter Replacement
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Hose Clamp (1) - Disengage [2x] - Hose Clamp Replacement Guidelines - Spring Type
Engine Oil Cooler Coolant Outlet Hose (2) @ Engine Oil Cooler - Remove
Engine Oil Cooler Coolant Inlet Hose (3) @ Engine Oil Cooler - Remove
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Engine Oil Cooler Bolt (1) - Remove [4x]
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Engine Oil Cooler (1) - Remove
Engine Oil Cooler Seal (2) - Remove and DISCARD [2x]
Reposition any hoses that will impede the removal of the starter.
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Auxiliary Generator Battery Jumper Cable Terminal Nut (1) - Remove
Auxiliary Generator Battery Jumper Cable (2) - Reposition away
Retainer (3) - Disengage
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Starter Stud (1) - Remove
Starter Bolt (2) - Remove [2x]
Reposition the starter to gain access to the electrical connections.
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Battery Positive Cable Nut (1) @ Starter Solenoid - Remove
Auxiliary Generator Battery Jumper Cable (2) - Remove
Electrical Connector (4) - Disconnect
Starter (3) - Remove
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NOTE:
The timing pin (3) is installed into the flexplate for engine timing procedures, it can be damaged if torque is applied to the flexplate with the timing pin engaged. The pin must be placed in the retracted position before torque is applied to the flexplate.

Install the EN-52476 Flywheel Holding Tool (2) through the starter mounting hole.
Release the EN-52476 Flywheel Holding Tool timing pin (1), use the crankshaft balancer bolt to rotate the engine until the timing pin snaps into the flex plate timing hole.

WARNING:

Refer to Diesel/Gasoline Vapors Warning .

WARNING:

Refer to Safety Glasses Warning .

Relieve the fuel system pressure. Fuel Pressure Relief
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Fuel Feed Pipe Bolt (1) - Remove
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Disconnect the fuel feed pipe (1) from the fuel pump and the fuel feed pipe - underbody. Metal Collar Quick Connect Fitting Service
Fuel Feed Pipe (1) - Remove
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Electrical Connector (1) - Disconnect [5x]
Wiring Harness (2) - Reposition
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Retainer (1) @ Upper Intake Manifold Bracket (2) - Unclip [4x]
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Upper Intake Manifold Cover Nut (1) - Remove [2x]
Radiator Surge Tank Inlet Hose Clip (2) @ Upper Intake Manifold Bracket (3) - Remove
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Upper Intake Manifold Cover Nut (1) - Remove [2x]
Upper Intake Manifold Bracket (2) - Remove
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Ignition Coil Bolt (1) - Remove [8x]
Ignition Coil (2) - Remove [4x]
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Electrical Connector (1) - Disconnect [2x]
Retainer (2) - Unclip [5x]
Engine Wiring Harness (3) - Reposition
Positive Crankcase Ventilation Tube (4) - Disconnect - Plastic Collar Quick Connect Fitting Service
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Retainer (1) - Unclip
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Camshaft Position Actuator Magnet Bolt (1) - Remove [4x]
Camshaft Position Actuator Magnet (2) - Remove [2x]
Camshaft Position Actuator Magnet Gasket (3) - Remove and DISCARD [2x]
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Timing Chain Upper Cover Bolt (1) - Remove [9x]
Timing Chain Upper Cover Bolt (2) - Remove

NOTE:

Use pry points indicated by arrows.

Timing Chain Upper Cover (3) - Remove
Timing Chain Upper Cover Seal (4) - Remove and DISCARD
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Camshaft Cover Core Hole Plug (1) - Remove [2x]
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Camshaft Cover Bolt (1) - Remove
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NOTE:
The engine may need to be rotated slightly using the crankshaft balancer until the locking pins of the EN-52462-A Camshaft Alignment Tool (1) drop into the slots in the camshafts.

EN-52462-A Camshaft Alignment Tool (1) - Install
Insert the EN-52462-A Camshaft Alignment Tool bolt (2) into the camshaft carrier and tighten to secure the tool to the camshaft carrier.
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Rotate both handles (4) of the EN-52462-A Camshaft Alignment Tool towards the rear of the engine as shown.

NOTE:

Ensure the camshaft carrier and cylinder head face are clean and free from RTV prior to installing the EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter.

EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) - Install [2x]
Install and tighten the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter bolts (3) to secure the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) to the cylinder head.
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EN-52461 Camshaft Torque Reaction Tool (1) @ EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapter (2) - Install
Install and tighten the 2 EN-52461 Camshaft Torque Reaction Tool bolts (3).
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Engage the tangs of the EN-52461 Camshaft Torque Reaction Tool (1) to the camshaft position intake and exhaust actuator slots as shown.
Tighten the 2 EN-52461 Camshaft Torque Reaction Tool bolts (2) to lock the camshaft position intake and exhaust actuators in place.
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Loosen the camshaft position actuator valve solenoid bolts (1).

CAUTION:

Hold the camshaft position actuator firmly and squarely during camshaft position actuator valve solenoid bolt removal/installation. Failure to do so may result in damage to the inside of the camshaft position actuator.

NOTE:

Pressure must be applied towards the engine on the EN-52461 Camshaft Torque Reaction Tool at points (3) prior to and during any time the following two conditions are simultaneously met.

The camshaft position actuator valve solenoid bolt (1) is loosened or removed.
The EN-52461 Camshaft Torque Reaction Tool bolts (2, 4) are loosened.

Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (2) to un-lock the camshaft position intake actuator.
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Tighten the lower portion of the timing chain around the crankshaft sprocket.
1. Use a wrench to turn the EN-52461 Camshaft Torque Reaction Tool (1) counter-clockwise 6 N.m (53 lb in), then hold.
2. Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (2) to lock the camshaft position intake actuator securely in place.
3. Remove the wrench from EN-52461 Camshaft Torque Reaction Tool (1).
4. Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (3) to un-lock the camshaft position exhaust actuator.
5. Use a wrench to turn the EN-52461 Camshaft Torque Reaction Tool (4) clockwise 6 N.m (53 lb in), then hold.
6. Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (3) to lock the camshaft position exhaust actuator securely in place.
7. Remove the wrench from EN-52461 Camshaft Torque Reaction Tool (4).
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EN-52436 Timing Chain Tensioner Retention Tool (1) @ Timing Chain (2) - Install
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Relieve timing chain tension from the camshaft position intake and exhaust actuators.
1. Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (2) to release the camshaft position intake actuator.
2. Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (2) to lock the camshaft position intake actuator securely in place.
3. Loosen the EN-52461 Camshaft Torque Reaction Tool bolt (3) to release the camshaft position exhaust actuator.
4. Tighten the EN-52461 Camshaft Torque Reaction Tool bolt (3) to lock the camshaft position exhaust actuator securely in place.
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Remove the camshaft position actuator valve solenoid bolts (1) and DISCARD.
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NOTE:
Hold the bottom of the camshaft postion exhaust actuator while disengaging the torque reaction tool to prevent the actuator from dropping.

Loosen the bolt (1) holding in the camshaft position exhaust actuator (3), then slide the barrel (2) of the torque reaction tool away from the camshaft position exhaust actuator (3).
Camshaft Position Exhaust Actuator (3) - Remove

NOTE:

Hold the bottom of the camshaft postion intake actuator while disengaging the torque reaction tool to prevent the actuator from dropping.

Loosen the bolt (1) holding in the camshaft position intake actuator (4), then slide the barrel (2) of the torque reaction tool away from the camshaft position intake actuator (4).
Camshaft Position Intake Actuator (4) - Remove
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Fuel Pump Shield Bolt (1) - Remove [2x]
Fuel Pump Shield Bolt (2) - Remove [2x]
Fuel Injection Pump Bracket (3) - Remove
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WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

Fuel Pump Insulator (1) - Remove
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Nut @ Fuel Feed Intermediate Pipe (1) - Loosen [2x]
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Fuel Injection Fuel Feed Pipe Bracket Bolt (1) - Remove
Fuel Feed Intermediate Pipe (2) - Remove and DISCARD
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Electrical Connector (1) @ Camshaft Carrier (3) - Disconnect [6x]
Electrical Connector (2) @ Camshaft Carrier (3) - Disconnect [6x]
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Engine Wiring Harness Bracket Nut (1) - Remove [2x]
Engine Wiring Harness Bracket (2) - Remove
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CAUTION:
The Positive Crankcase Ventilation (PCV) line is tamper resistant and must always be replaced once it is removed. The fittings connected to the PCV line must also be replaced if they are damaged when the PCV line is removed. To reduce the risk of damage to the fittings, use a suitable cutting tool and carefully cut the connections away.

NOTE:
Disconnecting the tamper resistant connections will damage the positive crankcase ventilation tube, it must be replaced after removal.

Positive Crankcase Ventilation Tube (1) - Remove and DISCARD
Remove the 2 EN-52461-200 Camshaft Torque Reaction Tool 2.7L Adapters, and the EN-52461 Camshaft Torque Reaction Tool.
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Camshaft Cover Stud (1) - Remove
Camshaft Cover Stud (2) - Remove [16x]
Camshaft Cover Bolt (3) - Remove [4x]
Camshaft Carrier (4) - Remove
Camshaft Cover Gasket (5) - Remove and DISCARD
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NOTE:
- Many internal engine components will develop specific wear patterns on their friction surfaces.
- Components MUST be separated, marked, or organized in a way to ensure installation to their original location and position. Take precautions in order to prevent interchanging of parts.
- Tag or mark each part immediately when removed. Indicate location, direction, or orientation when necessary.
Remove the 8 intake valve rocker arms (1) with hydraulic valve lash adjuster (2).
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Remove the 8 exhaust valve rocker arms (1) with hydraulic valve lash adjusters (2).
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Valve Rocker Arm (1) @ Hydraulic Valve Lash Adjuster (2) - Remove [16x]